Competence in cement, gypsum, sand & gravel

Unshakable.Under the harshest conditions.

Schenck Process Group –your partner worldwide

Acting locally to support your needs, the Schenck Process Group is working where you are.With a global network of Locations and competent partners, the name Schenck Process is synonymous throughout the world with process expertise and well-engineered measuring technology for industrial weighing, feeding, conveying, screening, automation and air filtration technology.

Our core competencies include feeding bulk materials, controlling flows of material, weighing goods, recording flows of goods, automating transport processes and planning processes up to turn-key deliveries.

Individual solutions for the most extreme conditions

The harsher the environmental conditions, the more resilient the technical systems must be. This particularly applies to industries such as cement and gypsum production.

Schenck Process Group offers these industries a wide range of reliable systems and sound application know-how.

Our products and applications provide control of continuous material flows; continuous weighing and feeding systems for coarse bulk materials, powders, dusts, fossil fuels and alternative fuels; screening technology; vibratory and volumetric mechanical feeding systems; pneumatic conveying systems; heavy load acquisition; and discontinuous weighing solutions.

Cement production

25 kg

1

1

Separator

Weighbridge

Clay and Sand

Apron conveyorMULTIBELT® belt weigher

Limestone SandClay

Reclaimer

Limestone SandClay

MoveMaster® Ebucket elevator

MULTISTREAM®

solid flow measuring unit

Raw mill

SeparatorHomo-genisationsilo

Flow gates

Clinker AdditivesGypsum

Calciner/Preheater

MULTIDOS® weighfeeders or apron weighfeeder

MULTIDOS® weighfeeders or apron weighfeeder

Weighbridge

Cementmill

MULTICOR® Smass flow meter

MULTICOR® Smass flow meter

MoveMaster® Ebucket elevator

Finished product

MechaTron® gravimetric feederRTN load cells

Finished product

Finished product

MULTICOR® Smass flow meter

Cement

MULTICOR® Smass flow meter

LOGiQ® loading and dispatch automation system (hardware & software)

Weighbridge MULTIRAIL® weighbridge

Bagging plant

LOGiQ®

ParcelledGoodsManager

LOGiQ®

LoadingManager

PFAor

CKD

GGBS

MULTICOR® Sblending unit

MoveMaster®

tube belt conveyor

DISOCONT®

MASTER mill controller

Limestonecrusher

Raw Material Handling Calciner & Kiln Feeding Cement Storage and Dispatch

Cooler

Rotary kiln

Storagesilo

Storagesilo

Pulver-izedcoal

MultiFlexscrew weighfeeder

MULTICOR® K coal dust feeding system

Primary fuel

MULTIBELT® BMCbelt weigher

Pneumaticconveying or

MULTIDOS® weighfeeder

IDMSblow through rotary valve

MoveMaster®

tube belt conveyor

MoveMaster® Echain conveyor

IntraBulk® MultiDock/EcoDockreception unit

Alternative (secondary) fuel

IntraBulk®

bulk reception unit

Raw material delivery

Flow gates

Raw meal

GGBSPFA

Additives, e.g.

FeSO4

DISOCONT®

MASTER mill controller

LinaClass® SLRcrusher relief vibrating screen

or

MULTICOR® S mass flowfeeder

MULTISTREAM® S solid flowfeeder

First the raw material for making the cement is broken up in a crusher. LinaClass® linear vibrating screens increase the effectiveness of the system by allowing pieces of the right size to bypass the crusher.

From here the material moves to the storage area, where the crushed stone is stored and homogenised in mixing beds. The mixture required to make a high-quality raw meal is mixed with MULTIDOS® weighfeeders and ground in ball or bowl mill crushers. The weighfeeders, which are precisely matched to the properties of the material, ensure smooth discharge from the silos.

The heating of the raw meal to make cement clinker takes place in rotary kilns at a temperature of around 1,450 °C. The raw meal is fed into the kiln by MULTICOR® mass flow feed devices, which exploit the Coriolis effect. The fuel supply is also managed by Schenck Process weighing and feeding equipment. The coal dust is precisely measured by the MULTICOR® K measuring devices and fed by the MULTICELL horizontal rotary feeders. The system can handle an output of a few hundred kilograms to 50 tonnes per hour with a feed accuracy of ± 0.5 %. The pulsation-free

25 kg

1

1

Separator

Weighbridge

Clay and Sand

Apron conveyorMULTIBELT® belt weigher

Limestone SandClay

Reclaimer

Limestone SandClay

MoveMaster® Ebucket elevator

MULTISTREAM®

solid flow measuring unit

Raw mill

SeparatorHomo-genisationsilo

Flow gates

Clinker AdditivesGypsum

Calciner/Preheater

MULTIDOS® weighfeeders or apron weighfeeder

MULTIDOS® weighfeeders or apron weighfeeder

Weighbridge

Cementmill

MULTICOR® Smass flow meter

MULTICOR® Smass flow meter

MoveMaster® Ebucket elevator

Finished product

MechaTron® gravimetric feederRTN load cells

Finished product

Finished product

MULTICOR® Smass flow meter

Cement

MULTICOR® Smass flow meter

LOGiQ® loading and dispatch automation system (hardware & software)

Weighbridge MULTIRAIL® weighbridge

Bagging plant

LOGiQ®

ParcelledGoodsManager

LOGiQ®

LoadingManager

PFAor

CKD

GGBS

MULTICOR® Sblending unit

MoveMaster®

tube belt conveyor

DISOCONT®

MASTER mill controller

Limestonecrusher

Raw Material Handling Calciner & Kiln Feeding Cement Storage and Dispatch

Cooler

Rotary kiln

Storagesilo

Storagesilo

Pulver-izedcoal

MultiFlexscrew weighfeeder

MULTICOR® K coal dust feeding system

Primary fuel

MULTIBELT® BMCbelt weigher

Pneumaticconveying or

MULTIDOS® weighfeeder

IDMSblow through rotary valve

MoveMaster®

tube belt conveyor

MoveMaster® Echain conveyor

IntraBulk® MultiDock/EcoDockreception unit

Alternative (secondary) fuel

IntraBulk®

bulk reception unit

Raw material delivery

Flow gates

Raw meal

GGBSPFA

Additives, e.g.

FeSO4

DISOCONT®

MASTER mill controller

LinaClass® SLRcrusher relief vibrating screen

or

MULTICOR® S mass flowfeeder

MULTISTREAM® S solid flowfeeder

transport of the material to the main burner and calciner is also engineered by Schenck Process. The clinker is then cooled to around 200 °C and weighed en route to the storage bins.

Alternative fuels such as fluff, sewage sludge and biomass are used as additional fuel sources. We offer complete solutions and components for highly accurate feeding of these materials.

In the final step the clinker is mixed with gypsum and other additives to make the finished cement. MULTIDOS® weighfeeders ensure the precision of the mix. It is then transported to the terminals for loading on to road or rail vehicles or ships. This stage is automated by the loading automation system LOGiQ®. Cement works are controlled from state-of-the-art, microprocessor-based control rooms, which receive all the data from the process. All weighing and feeding data is made available via field bus thanks to the electronic system DISOCONT® Tersus.

Legend:

Process steps covered by the Schenck Process Group

The main components of cement are limestone, clay and marl. From the quarry they are transported to a crusher system, where they are broken up. At this stage, products and applications from Schenck Process already come into play. LinaClass® linear vibrating screens, for example, increase the effectiveness of the crusher. And that's just the beginning.

From raw meal and clinker production to the high-quality final product, Schenck Process measuring and feeding technology plays a starring role in cement manufacturing, delivering perfect mixing, pulsation-free precision feeding and accurate weighing. At every stage of the process, under the toughest conditions and no matter how difficult the application, Schenck Process offers the cement industry a range of reliable and robust systems, economical solutions and extensive application know-how.

Efficient, economical and reliable at every stage of the processSchenck Process in the cement industry

Alternative fuelsReducing energy costs is a top priority for every company. To achieve this, one approach is to use alternative fuels for kilns and boilers such as shredded plastic and production waste, old tyres and grinding dusts, meat-and-bone meal and processed domestic waste. The Schenck Process system for alternative fuels is not only cost-effective, but also flexible.

Coal dust feedingSchenck Process provides perfectly adapted technology with the MULTICOR® K Coriolis coal dust feeding system, paired with the MULTICELL horizontal rotary feeder. This offers excellent wear resistance due to high-quality materials, with guaranteed feed accuracy of ± 0.5 % and a feed consistency of ± 1 %. It complies with statutory limit values for SOx, NOx and CO2 in the kiln and its emissions.

Feeding of powdered materials and meal Our effective and precise working solutions consist of three modules: the mass flow silo, various optimised feeding devices for the controlled extraction of material from the silo, and MULTICOR® S or MULTISTREAM® G, which are designed to measure the material flow. Schenck Process also provides silo engineering services to ensure that the extraction technology works properly.

Dense phase conveyingDense phase conveying is suitable for transporting difficult, abrasive or friable materials and pushes material along a pipe in a plug form at relatively low velocities. This means minimal wear on pipes / bends, promoting minimum maintenance and long life. Efficient use of compressed air also reduces power consumption and operating costs.

Continuous mix preparation for cement productionTo meet the quality requirements of the cement industry, there are two stages at which accurate mix preparation is essential. Firstly, the right relative amounts of raw materials need to be used, and secondly, special cements require the accurate addition of additives. Mix preparation is handled by MULTIDOS® weighfeeders. Whether the material is sticky or free-flowing, whether feeding kilograms or tonnes, there is a suitable weighfeeder for every requirement.

MULTIDOS®

Weighfeeder • For bulk solids with very

diverse properties • Feed rate up to 1,500 t/h • Accuracy up to ± 0.25 % • MechaTronic design

with integrated electronics • Belt width from 650 mm

up to 2,000 mm

MULTIDOS® VDPApron weighfeeder

• For difficult-to-extract bulk solids • Temperature range up to 250 ºC • Feed rate up to 1,000 t/h • Direct weighing technology • MechaTronic design

with integrated electronics • Belt width from 1,000 mm

up to 2,000 mm • Extraction moment up to 16,000 Nm

MultiFlexGravimetric screw feeder

• For all kinds of alternative fuels (explosive and non-explosive)

• Dust-proof, enclosed design • Minimum bulk density 0.05 t/m3

• Feed rate up to 300 m3/h • On-stream calibration possible

without additional equipment

GRAVIMETRIC FEEDING

GRAVIMETRIC FEEDING

GRAVIMETRIC FEEDING

MULTICOR® K / MULTICELL MC • Measuring system based on Coriolis

principle • Unaffected by outside influences • For coal with very diverse properties • Explosion-proof up to 10 bar, arrests

flame transmission • Accuracy ± 0.5 %, feed consistency ± 1 % • Feed rate up to 50 t/h • Combined with the MULTICELL horizontal

rotary feeder, forms a gravimetric feeding system

MULTICOR® S • Measuring system based on Coriolis

principle • Unaffected by outside influences • For dust and meal with very diverse

properties • Dust-proof design • Accuracy ± 0.5 % • Feed rate up to 1,000 m3/h (750 t/h) for

rotary kiln capacity of 10,000 t/day • Forms gravimetric feeding system by

use of metering hoppers, tailored to bulk solids requirements

GRAVIMETRIC FEEDING

GRAVIMETRIC FEEDING

GRAVIMETRIC FEEDING / WEIGHING

MechaTron® Coni-FlexLoss-in-weight-feeder

• For powders, granulates, chips and fibres

• Special design for ferrous sulfate available

• Volumetric or gravimetric bulk solids feeding

• Feed hopper with flexible wall • Feed accuracy better than ± 0.5 % • Feed rate up to 32,000 dm3/h

IDMS Blow-through rotary valve

• For all kinds of alternative fuels (explosive and non-explosive)

• Compact, space-saving design while offering high power density

• High and constant fill levels thanks to large inlet cross-section

• Highly abrasion-resistant wearing parts and long service life

• Reliable pneumatic conveyance thanks to constant leakage air

• Robust construction in line with German industry standards

MULTICOR® R • Measuring system based on Coriolis

principle • Unaffected by outside influences • For dust and meal with very diverse

properties • Dust-proof design • Weighing module with wireless

data transmission • Accuracy ± 0.5 % • Feed rate up to 800 m3/h

(600 t/h) for rotary kiln capacity of 10,000 t/day

• Forms gravimetric feeding system by use of metering hoppers, tailored to bulk solids requirements

MULTISTREAM® G • Uses the deflection chute measuring

principle • For dust and meal with very diverse

properties • Dust-proof housing • Feed rate up to 1,250 m3/h

(1,000 t/h) for rotary kiln capacity of 10,000 t/day

• Forms gravimetric feeding system by use of prefeeders, tailored to bulk solids requirements

CONVEYINGGRAVIMETRIC FEEDING / WEIGHING

GRAVIMETRIC FEEDING / WEIGHING

MULTIBELT®

Belt weigher • For all kinds of bulk solids • Accuracy up to ± 0.25 % • Feed rate up to 20,000 t/h • Belt width from 500 mm

up to 2,000 mm • Suitable for use in ATEX zones • Design for clinker measurement in

bucket conveyor systems available

• Legal-for-trade model available

GRAVIMETRIC WEIGHING GRAVIMETRIC WEIGHING WEIGHING ELECTRONICS

MULTIRAIL® LegalWeightTrain weighing

• Dynamic railway scale for all wagon types

• Legal-for-trade accuracy • No foundation • No rail gap • Fully automatic operation • Very quick installation • Static/dynamic platform weighbridges

also available

DISOCONT® TersusWeighing and feeding electronics

• For control of all kinds of continuous weighing and feeding applications

• In field or control cabinet installation • Communication with PLC by field bus

technology (Profibus, Modbus, DeviceNet etc.)

• Commissioning and diagnostics supported by graphics

• Wireless access for service

Mechanical conveyingand MoveMaster®

Bulk conveying • Tube belt conveyor

Three-dimensional transportation over long distances (up to approx. 1,000 m) and problematic topographic areas

• U belt conveyor Conveying powdery and granular materials horizontally

• Corrugated belt conveyor Cross rigid belt with deads and sidewalls, inclined or vertically upward material conveying

• En-masse chain conveyor Horizontal and/or upward material conveying (max. inclination 75º) over medium distances (up to 70 m)

LOGiQ® Loading Automation • Logistics solution for bulk materials

and cargo industry • Automation of all loading processes

from ordering through to shipment • Faster loading due to accurately

defined processes • Mass flow management of incoming

and outgoing materials by road, rail and ship

IntraBulk®

Truck unloading • IntraBulk® MultiDock

• Screw extractor floor with five screws• Designed for trucks with walking floor or

tipping trucks• Unloading capacity up to 500 m3/h• Dust extraction system for trucks with

walking floor• For various types of RDF

• IntraBulk® EcoDock• Screw extractor floor with five screws• Designed for trucks with walking floor• Unloading capacity up to 100 m3/h• For various types of RDF

• IntraBulk® BRU• Receiving buffer hopper and apron feeder

as link to the downstream process• For various products• Dust extraction system• Installation below and above ground• Unloading capacity up to 500 m3/h

CONVEYING RECEPTION LOGISTICS AUTOMATION

Complete solutions for your after-sales requirements

Looking for after-sales solutions? Our extensive Process Advanced Service System (PASS) provides you with after-sales services – customised to your specific requirements.

The framework of our PASS program is designed with you in mind. With the guidance of our experienced after-sales team, you can create PASS packages comprising original spare and wear parts, various services and high quality components to meet your needs.

PASS is based on a modular principle. You choose individual PASS products or a combination thereof as required. The products are classified in four categories to make it easier for you to find the right modules.

We will happily provide you with individual consultation, either as part of a PASS contract or on individual enquiry.

Whatever Full Service means to you – let’s create it together!

Our PASS service categories

Repair

Inspection

Management

Support

No matter what materials you use, processes need to run smoothly. When processing your products, if you want complete peace of mind that materials and machines are perfectly matched, realistic tests in our TestCenters are what you need.

Schenck Process TestCenters worldwide.Test results you can rely on.

Schenck Process has an extensive materials database covering over 10,000 samples for which characteristics such as particle size distribution, shape, porosity, bulk density, temperature, moisture content, fragility and air retentiveness have been measured and the most suitable conveying method determined.

This practical experience is invaluable in determining the most effective solution for a customer's application and details of every new test are added to the database.

This resource is also available to customers who independently need to establish the flow characteristics of a material or to help solve on-site problems with existing or competitor systems.

The Schenck Process Group is a global leader in industrial weighing and feeding technology /// screening and separation systems for bulk materials /// dust collection and air filtration technology /// pneumatic and mechanical conveying solutions /// automation and diagnostic technology

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Schenck Process GmbHPallaswiesenstr. 10064293 Darmstadt, GermanyT +49 61 51-15 31 29 53heavy@schenckprocess.comwww.schenckprocess.com

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